Reusable stainless steel bottle for transporting and storing liquids and a method for manufacturing thereof

ABSTRACT

A reusable stainless steel bottle for transporting and storing of liquids has a cylindrical shape and includes the following components: an upper cylindrical portion (1) and a neck (3) connected thereto, and a lower cylindrical portion (2), wherein all the components of the bottle are connected with each other with weld seams (4, 6), and at least one of the weld seams (4, 6) forms a reinforcing rib.

The invention refers to containers for safe storage and transporting of liquids, in particular, potable water, soft drinks, juices, wine, beer, milk, etc., more particularly to small, medium and large size reusable bottles to be filled with potable water at the automated water filling lines, with the subsequent use in water coolers, including pumps, as well as for household use, and a method for manufacturing thereof.

The most commonly used bottles for transporting and storing potable water are bottles from plastic materials, in particular, from polycarbonate and polyethylene terephthalate (PETP). Polycarbonate is obtained by polymerization of bisphenol A and phosgene (COCl₂). Bisphenol A is a compound structurally similar to estrogen group hormones, which is obtained by phenol condensation with acetone in the presence of catalysts, such as hydrochloric acid, and has been used in plastic industry since 1960s. Polyethylene terephthalate is a heterochain polyester of terephthalic acid and ethylene glycol, which is obtained by polycondensation of components. Polyethylene terephthalate has been used since late 1940s and it is a very common member of the class of polyesters known under different names: PETPH, PETP, PET, polyester, laysan, etc.

It has been currently established that bisphenol A as a feedstock for polycarbonate has a negative effect on brain and reproductive system, and causes a range of cancers, in particular, prostate, ovary and breast cancer. Therefore, polycarbonate is a potentially hazardous material, which is banned for manufacture in respect of baby products in a number of countries.

The advantage of bottles from PETP is the absence of bisphenol A and, therefore, their safety for human health. Their advantages also include high impact strength, whereby bottles from PETP do not break, low temperature resistance and low odor absorption. Drawbacks of bottles from PETP include lower high temperature resistance as compared to polycarbonate and their complicated recycling (for example, by incineration or processing into secondary products). At the temperature of over +60° C. a body of such bottle is softened and can change its shape. Specifically at such temperature the most of bacteria and undesirable microorganisms are destroyed. Moreover, drawbacks of bottles made from PETP consist in that they undergo scratching and lose their attractive appearance rather quickly. For that reason they are usually used with protective disposable bags. The essential drawback of PETP containers is their relatively low barrier properties. It transmits ultraviolet rays and oxygen and emits carbon dioxide thereby deteriorating and shortening shelf life of liquids.

In view of the above-stated, there has always been an object in the field of bottled water manufacture to find an alternative to bottles manufactured from polycarbonate and PETP.

Unfortunately, glass, as the most environmentally friendly material, is hardly suitable for use in the field of bottled water manufacture due to excessive weight of bottles made from it, as well as a risk of their breakage during transportation. Furthermore, glass may have internal chips that can bring about ingress of glass particles into liquid.

For that reason, stainless steel is a promising alternative material to replace polycarbonate and PETP, which, along with glass, is considered as one of the best and health friendly material suitable for direct contact with food products and water. The surface of stainless steel is not subjected to corrosion upon contact with water having alkaline or acidic pH value. It has no pores or flaws where microbial flora proliferation is possible. An additional advantage of stainless steel consists in its nontransparency, which prevents from microbial flora proliferation within the product or water under exposure to light. Low thermal conductivity is also an advantage of stainless steel. For that reason local heating of a container made of stainless steel does not lead to fast heating of the whole product of water held in such container, and stainless steel does not react with water.

Stainless steel bottles of various capacities (2 L, 5 L, 10 L and 20 L) commercially available from Cole-Parmer and intended for use in medical industry as laboratory equipment are known from the prior art http://www.coleparmer.com/Category/Stainless_Steel_Bottles/56701. Such containers are produced by casting, they have thick walls and, accordingly, heavy weight. Their design, especially their neck, mares them unsuitable for use in the field of bottled water manufacture. Their high cost also contributes to disadvantages of the known containers.

A reusable stainless steel bottle for storage and transportation of potable water is known from the prior art. The known bottle has a cylindrical shape or prismatic shape with rounded edges and reinforcing ribs to render appropriate strength to the bottle. The bottle may be closed at automated potable water filling line (UA 83871 U, published on Sep. 25, 2013).

A drawback of the known bottle consists in its complicated design, which requires a plurality of reinforcing ribs to render strength to the bottle, excessive weight and low quality of internal surface polishing, which impacts on the quality of water.

The inventions is based on the object of providing a health friendly reusable stainless steel bottle for transporting and storing liquids, in particular, potable water, having a simplified design and suitable for extensive use in common areas and in household setting.

The object of the invention is achieved by the fact that in the reusable stainless steel bottle for transporting and storing liquids, which has a cylindrical shape and includes the following components: an upper cylindrical portion and a neck connected thereto, and a lower cylindrical portion, according to the invention, all components of the bottle are connected with each other with weld seams, at least one of said weld seams forming a reinforcing rib.

Further, the reinforcing rib is formed by the weld seam, which connects the upper cylindrical portion and the lower cylindrical portion.

Further, the neck is intended to be used at the automated potable water filling line and subsequent closure of bottles with a standard plug, and a subsequent use of the bottle along with a water cooler or with pumps of various designs.

Further, the neck is provided with a thread for screwing-on a cap or a threaded cover for a household version of the use.

Further, the internal surface of the bottle is smooth, without substantial protrusions and depressions.

Further, the bottle includes an additional reinforcing rib in the place of connection of the neck with the upper cylindrical portion.

The subject matter of the invention is also a method of manufacture of a reusable bottle from thin sheet stainless steel, the method included the following stages:

-   -   forming round flat workpieces from thin sheet stainless steel;     -   production of the lower cylindrical portion and the upper         cylindrical portion from the round flat workpiece by die         stamping (cold-drawing);     -   forming shaped edges at the places of future connection of the         upper cylindrical portion with the lower cylindrical portion;     -   forming an opening for the neck in the upper cylindrical         portion;     -   forming a neck from a cylindrical tube;     -   connection of the neck with the upper cylindrical portion by         welding;     -   polishing the upper cylindrical portion and the lower         cylindrical portion from inside,     -   removing a superfluous metal around the edge

wherein, according to the invention, the shaped edges in the upper cylindrical portion and the lower cylindrical portion are connected by welding, thereby forming a reinforcing rib.

Further, the outer surface of the bottle is subjected to polishing.

Further, the neck is made compatible for the use at the automated potable water filling line, with the subsequent closure of bottles, as well as the use with a water cooler or a pump.

Further, a thread is formed on the neck for screwing-on a cap or a cover.

Further, stainless steel of 0.2 mm to 2 mm in thickness is used for production of the bottle.

Further, for welding components of the bottle together, welding type is used selected from the group consisting of MIG/MAG, TIG, laser-beam weld and MMA.

Further, for welding components of the bottle together TIG argon arc welding is used.

Further, the bottle is intended for transporting and storing liquids selected from the group including potable water, soft drinks, juices, wine, beer and milk.

Further, the liquid is potable water.

According to the invention, the second embodiment of the claimed bottle is also proposed.

According to the second embodiment, in the reusable stainless steel bottle for transporting and storing liquids, which has a cylindrical shape and includes the following components: an upper portion and a neck connected thereto, a middle cylindrical portion, a lower portion, according to the invention, all components of the bottle are connected with each other with weld seams, wherein said vertical weld seam on the middle cylindrical portion form a reinforcing rib.

Further, the neck is intended to be used at the automated potable water filling line and subsequent closure of bottles with a standard plug, and the subsequent use of the bottle along with a water cooler or with pumps of various designs.

Further, the neck is provided with a thread for screwing-on a cap or a threaded cover.

Further, the internal surface of the bottle is smooth, without substantial protrusions and depressions.

Further, the bottle is intended for transporting and storing liquids selected from the group including potable water, soft drinks, juices, wine, beer and milk.

Further, the liquid is potable'water.

For better understanding of the invention, the following drawings are provided.

FIG. 1 shows a general view of the reusable stainless steel bottle manufactured according to the invention.

FIG. 2 shows a general view of the upper cylindrical portion with a formed “shaped edge” at the place of joint of the upper cylindrical portion with the lower cylindrical portion prior to the procedure of their welding.

FIG. 3 shows a general view of the lower cylindrical portion with the formed “shaped edge” at the place of joint of the upper cylindrical portion with the lower cylindrical portion prior to the procedure of their welding.

FIG. 4 shows a general exploded view of elements of the reusable stainless steel bottle manufactured according to the second embodiment.

FIG. 1 shows the reusable stainless steel bottle composed of the upper cylindrical portion 1, which represents a hollow cylinder whose upper portion in this embodiment smoothly transitions into a truncated conical apex of the lower cylindrical portion 2 and the neck 3. In another embodiment, the surface of the upper portion may be flat. The upper cylindrical portion 1 and the lower cylindrical portion 2 are connected with each other by a weld seam at the place of joint of shaped edges of the upper cylindrical portion 1 and the lower cylindrical portion 2 with formation of a reinforcing rib 4. FIG. 2 shows the “shaped edge” 5 a in the upper cylindrical portion 1. FIG. 3 shows the arrangement of the “shaped edge” 5 b on the lower cylindrical portion 2.

The claimed reusable stainless steel bottle is manufactured using the following process.

Two round workpieces are formed, for example, from flat sheet AISI 304 grade stainless steel 0.2-2.0 mm thick. It should be noted that, in order to decrease the bottle's weight, it is preferable to use stainless steel as thin as possible. From one round flat workpiece, the lower cylindrical portion 2 is formed by die stamping (cold-drawing). Using the subsequent stamping operation the shaped edge 5 b for future welding is formed on the lower cylindrical portion 2. The inner surface of the lower cylindrical portion 2 is subjected to polishing. Using a trimmer die excess metal around the edge is removed. The lower cylindrical portion 2 is subjected to flushing out. The upper portion 1 is formed from the second round flat workpiece by die stamping, said portion having a cylindrical shape that transitions into a conical shape. Using the subsequent stamping operation at the bottom of the upper cylindrical portion 1, the shaped edge 5 a for future welding is formed, which by its size and shape represents a mirror reflection of the edge on the lower cylindrical portion 2. Using a trimmer die, an opening corresponding to the size of the neck is cut out in the upper cylindrical portion 1 with a conical top. In order to connect the components of the bottle with one another, it is preferable to use welding, in particular, MIG/MAG, TIG, laser-beam weld and MMA, or any other type of welding suitable for welding of stainless steel components. T.I.G. (tungsten inert gas) is considered as the best type of welding. Welding units developed by the authors of the invention provide for: A. Precise centering the place of connection of the neck to the upper cylindrical portion and their welding together. B. Precise centering and welding the shaped edges of the upper cylindrical portion 1 and the lower cylindrical portion 2. In the process of welding the components of the bottle, the speed of rotational movement of connected and centered upper cylindrical 1 and lower cylindrical 2 portions about their axes, the current frequency and the welding arc power are adjusted experimentally. In the process, argon gas is supplied to the place of connection, both from the outside and from the inside. Such welding technique provides for a sufficient surface finish class of the inner seam. Welded shaped edges of the upper cylindrical 1 and the lower cylindrical 2 portions, along with the welding seam forming the reinforcing rib 4 of the claimed bottle. The inner surface of the upper cylindrical portion 1 and the place of welding are subjected to polishing from inside. Excess metal around edges is removed prior to welding.

The neck 3 is manufactured from a cylindrical tube by machine turning of the surface. The welded upper and lower portions, together with the neck, are subjected to flushing out. A semiautomated machine designed by the authors of the invention, and intended for tight pressing and ideal centering the upper cylindrical portion 1, together with the neck and the lower cylindrical portion 2, provides for their uniform rotation and welding with simultaneous formation of the reinforcing rib. Such design has no counterparts in the field of manufacture of articles from thin sheet stainless steel, therefore, the present method and the bottle manufactured using it have substantial features of novelty. According to one of the embodiments, an additional reinforcing rib 6 is formed in the place of connection of the neck 3 with the upper cylindrical portion 1 by means of a weld seam. Thereafter, polishing of the outer surface of the bottle is carried out.

FIG. 2 shows a general view of the upper cylindrical portion with a formed “shaped edge” 5 a at the place of joint of the upper cylindrical portion 1 with the lower cylindrical portion prior to the procedure of their welding.

FIG. 3 shows a general view of the lower cylindrical portion 2 with the formed “shaped edge” 5 b at the place of joint of the upper cylindrical portion with the lower cylindrical portion prior to the procedure of their welding.

The reusable stainless steel bottle according to the second embodiment of the invention in exploded view is shown in FIG. 4. The bottle includes a neck 3, an upper portion 7, which in this embodiment has a conical shape, a middle cylindrical portion 8, and a lower portion 9, which in this embodiment has a cup shape. All elements of the bottle are connected with each other with weld seams. The upper portion 7 and the lower portion 9 are manufactured by die stamping, while the middle cylindrical portion 8 is manufactured by rolling workpieces from a rectangular sheet of stainless steel and welding with a vertical weld seam forming a reinforcing rib 10.

The bottle shown in FIG. 4 is manufactured as follows.

The upper 7 and the lower 9 portions are made from thin sheet stainless steel 0.2-2.0 mm thick by die stamping from round workpieces prepared with the use of a trimmer die. In the process, a round opening having dimensions that correspond to the external diameter of the neck is formed in the upper workpiece using the trimmer die. The middle cylindrical portion 8 is also manufactured from a rectangular sheet of stainless steel having appropriate dimensions by preliminary rolling and the subsequent welding using an argon arc welding device or a laser device with a vertical weld seam, which also functions as a reinforcing rib 10. The neck 3 is made from a tubular workpiece of stainless steel by machine turning of its surface, with formation of necessary grooves and the appropriate upper edge to be compatible with a cap for automated closure at the filling line for liquids, for example, water. To prepare all four components they are connected with each other by welding. So, the neck 3 is welded to the upper portion 7 and then the lower portion 9 and the upper portion 7 together with the neck 3 are welded to the middle cylindrical portion 8. Thereafter, the weld seams are thoroughly polished. 

1. A reusable stainless steel bottle for transporting and storing liquids, which has a cylindrical shape and includes the following components: an upper cylindrical portion and a neck connected thereto, a lower cylindrical portion, characterized in that all the components of the bottle are connected with each other with weld seams, and at least one of the weld seams forms a reinforcing rib.
 2. The bottle according to claim 1, wherein the reinforcing rib is formed by the weld seam, which connects the upper cylindrical portion and the lower cylindrical portion.
 3. The bottle according to claim 1, wherein the neck is intended to be used at the automated potable water filling line and subsequent closure of bottles with a standard plug, and the subsequent use of the bottle along with a water cooler or with pumps of various designs.
 4. The bottle according to claim 1, wherein the neck is provided with a thread for screwing-on a cap or a threaded cover.
 5. The bottle according to claim 1, wherein the internal surface of the bottle is smooth without substantial protrusions and depressions.
 6. The bottle according to claim 1, wherein the bottle includes an additional reinforcing rib in the place of connection of the neck with the upper cylindrical portion.
 7. The bottle according to claim 1, wherein the bottle is intended for transporting and storing liquids selected from the group including potable water, soft drinks, juices, wine, beer and milk,
 8. The bottle according to claim 7, wherein the liquid is potable water.
 9. A method for production of the reusable bottle according to claim 1, the method includes the following steps; forming round flat workpieces from thin sheet stainless steel; production from the round flat workpieces of the lower cylindrical portion and the upper cylindrical portion by die stamping (cold-drawing); forming shaped edges at the places of future connection of the upper cylindrical portion with the lower cylindrical portion; forming an opening for the neck in the upper cylindrical portion; forming a neck from a cylindrical tube; connection of the neck with the upper cylindrical portion by welding; polishing the upper cylindrical portion and the lower cylindrical portion bottle from inside, characterized in that the shaped edges in the upper cylindrical portion and the lower cylindrical portion of the bottle are connected by welding, thereby forming the reinforcing rib.
 10. The method according to claim 9, wherein an additional reinforcing rib is formed in the place of connection of the neck with the upper cylindrical portion.
 11. The method according to claim 9, wherein the outer surface of the bottle is subjected to polishing.
 12. The method according to claim 9, wherein the neck is made compatible for the use at the automated potable water filling line, with the subsequent closure of bottles, and the subsequent use in water coolers or with a pump.
 13. The method according to claim 9, wherein a thread is formed on the neck for screwing-on a cap or a cover.
 14. The method according to claim 9, wherein stainless steel of 0.2 mm to 2.0 mm in thickness is used for production of the bottle.
 15. The method according to claim 9, wherein the welding type selected from the group consisting of MIG/MAG, TIG, laser-beam weld and MMA is used for welding the components of the bottle together.
 16. The method according to claim 15, wherein TIG argon arc welding is used for welding the components of the bottle together.
 17. A reusable stainless steel bottle for transporting and storing liquids, which has a cylindrical shape and includes the following components: an upper portion and a neck connected thereto, a middle cylindrical portion, a lower portion, characterized in that all the components of the bottle are connected with each other with weld seams, and the vertical weld seam on the middle cylindrical portion forms a reinforcing rib.
 18. The bottle according to claim 17, wherein the neck is intended to be used at the automated potable water filling line and subsequent closure of bottles with a standard plug, and the subsequent use of the bottle along with a water cooler or with pumps of various designs.
 19. The bottle according to claim 17, wherein the neck is provided with a thread for screwing-on a cap or a threaded cover.
 20. The bottle according to claim 17, wherein the internal surface of the bottle is smooth without substantial protrusions and depressions.
 21. The bottle according to claim 17, wherein the bottle is intended for transporting and storing liquids selected from the group including potable water, soft drinks, juices, wine, beer and milk.
 22. The bottle according to claim 21, wherein the liquid is potable water. 